Source Sans Variable, Half baked?

Letter overlaps are very common with Variable Fonts. I rarely see variable fonts that don't have at least some overlapping shapes. The overlaps provide a clue of how the fonts are built and how they function. The letters behave like a live object blend. The visible letters are merely one possible step of many in-between various design instances.

I like the creative flexibility variable fonts can provide versus that of static fonts. But they also represent a potential hazard in production if the graphics being created have to be cut out of any material. If I want to rout acrylic faces for a set of lighted channel letters the letter overlaps must be removed before the job is sent to the computerized routing table. The tool bit will cut wherever it sees a path. The overlaps are easy to remove by using the Unite Pathfinder command.